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Studies of parts failure due to wear and corrosion have shown that most of these failures occur on the surface of the material. The surface engineering technology is used to treat the surface of the material to improve the surface properties of the material, which will effectively extend the service life of the parts. Therefore, surface engineering plays an important role in the petroleum and petrochemical industry.
Thermal spraying technology is an important surface treatment technology in surface engineering. It refers to the maintenance of the original performance of the material of the part body, by preparing a layer of superior performance on the surface of the surface to impart wear and resistance to the surface of the part. Corrosion, high temperature resistance, oxidation resistance, fatigue resistance and many other properties. The biggest advantage of using thermal spray technology is that it can produce a thin layer of surface function superior to the properties of the bulk material in a variety of ways, the thickness of which is only a few tenths of the structural size, but the part has a higher than the bulk material. Wear resistance, corrosion resistance and high temperature resistance. Even with expensive, rare elements with excellent performance, there is no significant cost increase. In addition, thermal spray technology can directly target local surface strengthening, repair and pre-protection for the failure of many valuable components to achieve the purpose of extending service life or regaining value. Therefore, the economic and social benefits of using thermal spray technology are enormous.
Characteristics of thermal spraying technology and its common methods
The thermal spraying technique heats a certain wire or powdered material to a molten or semi-molten state by a heat source such as a flame, an arc or a plasma, and accelerates the formation of a high-speed droplet, which is sprayed toward the substrate to form a coating layer thereon. This cover layer is called a spray coating.
Compared to other surface coating technologies, thermal spray technology has the following characteristics:
(1) Various methods. There are more than a dozen thermal spray methods, providing a variety of means for preparing coatings.
(2) The coating base material is not limited. Thermal spraying can be used to prepare coatings on almost all solid surfaces, such as metallic materials, inorganic materials (glass, ceramics), and organic materials (wood, cloth, paper).
(3) A wide range of types of spray materials are available. Almost all metals, alloys, ceramics, plastics, etc. can be used as spray materials.
(4) The size, size and shape of the object to be painted are not limited. It can be used for large-area spraying of large equipment or for spraying parts of the workpiece. Both the parts can be sprayed and the finished structure can be sprayed.
(5) It can impart special surface properties to ordinary materials. The material can meet the special performance requirements of wear resistance, corrosion resistance, high temperature oxidation resistance, heat insulation and sealing, thereby saving precious materials, improving product quality and meeting the needs of various engineering and cutting-edge technologies.
(6) The coating thickness is easier to control. The thin one can be several tens of micrometers, and the thick one can be several millimeters.
(7) Low cost. The economic benefits are significant.
It can be seen that the thermal spraying technology has the characteristics of flexible process, strong applicability, easy promotion, economic and other processes, and plays an important role in surface engineering. At present, the most widely used methods in production practice are flame spraying (including wire flame spraying, powder flame spraying, explosive spraying, supersonic flame spraying), plasma spraying and arc spraying.
Application Status of Thermal Spray Technology in Petroleum and Petrochemical Industry
1. Repairing petroleum machinery
With the continuous development of advanced manufacturing technology and equipment engineering, manufacturing and maintenance will become more and more unified, and "maintenance" has been given a broader meaning. In 1984, the US "Technical Review" advocated the renovation or regeneration of old products and called "remanufacturing." The energy required for remanufacturing is about 20% to 60% of the new product, and the price is only 40% to 60% of the new product. Many of the old parts that have been treated with thermal spray technology perform better than new ones.
Some high-power crankshafts in equipment such as oil rigs, and various heavy-duty vehicles, tractors, and crankshafts of diesel engines used in oil fields can be repaired by thermal spray technology. For example, it can be repaired by arc spraying 3Cr13 coating or plasma sprayed ceramic coating. This can significantly reduce the cost and extend the service life of the equipment, especially the problem of repairing imported equipment. Thermal spray methods can also be used to restore oversized parts or to strengthen the surface of wear parts.
Parts such as plungers, cylinder liners, and impellers of various types of pumps used in oil fields can be repaired by various thermal spraying methods. If it can be repaired and strengthened by supersonic flame spraying WC-12Co or plasma spraying Al2O3, it can also be repaired by arc spraying 1Cr13 steel wire. The life of the plunger repaired by thermal spraying is higher than that of the surface hardened plunger, which is slightly lower than the plunger of the nickel-based alloy sprayed on the working surface. For some large-diameter plungers, thermal spray is the best repair method without deformation and low cost due to deformation and cannot be repaired by spray welding. A 12-ton plunger has been repaired in China, and the spray coating weighs 33 kilograms. After the coating is sealed, the performance is better than that of the new plunger, and the cost is only 1/4 of the new plunger. The high-power motor rotor used in oilfield water pump motor and refining and salination system can be repaired by thermal spraying technology.
2, improve the wear resistance of mechanical parts
The catalytic cracking unit of the refinery generally uses a flue gas energy recovery system. However, since the flue gas turbine works under the high-temperature flue gas flow with solid catalyst particles and corrosive medium, the moving and static blades and the like are easily eroded, and the service life is only 2 to 12 months. The use of plasma spraying technology to spray alloy powder on the surface of moving and static blades can improve the erosion and wear resistance of dynamic and static blades, thus prolonging the service life of the flue gas turbine.
3. Spraying petroleum machinery parts
Wear-resistant and corrosion-resistant ball valve: For metal seat ball valves in pipes with corrosive mortar at temperatures up to 540 ° C and pressures up to 140 MPa, apply supersonic flame spray WC-Co coating, Cr2C3-NiCr coating, Fe-Cr -Ni-Mo coating or WC-Ni coating can greatly improve the corrosion resistance and erosion resistance of the ball valve, improving the reliability and life. Sucker rod: In order to meet the needs of corroding oil well production, the US has produced stainless steel sucker rods with AISI 431 stainless steel material, which is characterized by good corrosion resistance but high cost. In order to save costs, ContinentalOilCompany used AISI316 stainless steel powder to plasma-spray API C-class and D-class sucker rods to make stainless steel sucker rods. The sucker rods also have anti-corrosion properties, but the cost is better than stainless steel. It is cheaper. Pumping pump plunger: The general methods for domestic processing of oil well pump plunger are: surface chrome plating, electroless nickel-phosphorus plating and surface spray-welded nickel-based alloy. Currently, thermal spray ceramic coatings have been used as a new treatment process to manufacture pump plungers. A ceramic coating was formed by spraying a ceramic material of 87% Al2O3 + 133% TiO2 on the surface of the plunger by thermal spraying. A pump plunger made in this way. The running time in sand-containing wells can last for more than two months. Its life is twice that of a plunger made in a conventional process. Drill bit: Explosive spray WC-Co coating is successfully applied to the drill bit to improve the wear resistance, corrosion resistance and erosion resistance of the drill bit. The composite alloy coating can also be prepared on the surface of the synthetic diamond drill bit by plasma spraying.
4. Anti-corrosion of containers, pipes and towers
The towers, tanks and pipelines used in the oil field can be arc-sprayed with aluminum, zinc, stainless steel and other coatings for corrosion protection or flame spray plastic preservation. DuPont, United Chemical, Shell and other companies have used a large number of wires on the inner wall of the reaction generator to spray stainless steel, stellite, molybdenum and titanium alloys. Plasma spraying, supersonic flame spraying, and arc spraying can solve the corrosion and erosion problems of various boiler tubes used in oil fields.
Application Status of Thermal Spray Technology in Petroleum and Petrochemical Industry
Corrosion and wear are serious problems that jeopardize the production of the petroleum and petrochemical industry. According to the survey, the direct economic losses caused by wear and corrosion in China's petroleum and petrochemical industry amount to several hundred million yuan each year. The corrosion and wear of pipelines, storage tanks, oil well casings and other facilities in China's petroleum industry are becoming more and more serious with the development of China's oil and gas fields and the service life of equipment; while in China's petrochemical industry, with the import of high sulfur The refining of crude oil and the corrosion of equipment are also becoming more and more serious. Therefore, the adverse effects of corrosion and wear on the safe and stable operation of equipment will become more and more prominent, and it is urgent to improve the wear resistance and corrosion resistance of mining and processing equipment in the petroleum and petrochemical industry.